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Perspective-
Material Modeling and Mold Analysis
Hubert Lobo
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A look back
Advent of simulation- early successes
Melt-solid transitions- the case for a
unified material model
Post-fill- PVT and the prediction of
shrinkage
Viscous heating- impact on flow behavior,
degradation
Why CRIMS has to work so hard
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Advent- pre 1990
Solid scientific study into
rheology (Hieber et al)
Very strong rheological
models
Relatively simple simulation-
fill patterns
u Modest effect of phase change
u Rheology, thermal property
controlled behavior
( )
( )
( )
( )
( )
( )
( )
N A A D D D
P
T
Pa
P D D T
T T A
T T A
D
N
: Unknowns
Pa Pressure
C e Temperatur
sec Rate Shear
sec . Viscosity
exp
1
*
2 1 3 2 1
1 -
3 2
*
*
2
*
1
1 0
1
*
0
0
t

q
q
t
q
q
q

+ =
(

+

=
|
.
|

\
|
+
=

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Post-Filling Challenges
Simulation highly sensitive to very
slightly varying property behavior
(PVT)
u Location/nature of transition
u Absolute values of PVT properties
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The PVT controversy
C-MOLD- process is in cooling-
measure PVT in cooling
Moldflow- Measure PVT while
heating
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The PVT controversy-
Realities
0.90
0.95
1.00
1.05
1.10
1.15
100 150 200 250 300 350
Temperature C
s
p
.
v
o
l

(
c
m
3
/
g
)
PVT 10 MPa, Isobaric Heating
PVT 40 MPa Isothermal Cool
No super-cooling
Solid state not
representative
0.90
0.95
1.00
1.05
1.10
1.15
100 150 200 250 300 350
Temperature C
s
p
.
v
o
l

(
c
m
3
/
g
)
PVT 10 MPa, Isobaric Heating
PVT 10 MPa, Isobaric Cooling
PVT 40 MPa, Isobaric Cool
PVT 40 MPa Isothermal Cool
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Accounting for rate with DSC
0.90
0.95
1.00
1.05
1.10
1.15
1.20
25 75 125 175 225 275 325
Temperature C
s
p
.
v
o
l

(
c
m
3
/
g
)
-10
0
10
20
30
40
50
60
100 C/min Kinetics
0 MPa
PVTmodel 0 MPa, 3C/min
PVT 10 MPa, 3C/min
DSC 0 Mpa, 100C/min
Lobo, Gordon Conference 98, Antec 99
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Limitations
Good for quiescent situations
Supercooling effect overpredicted
when there is flow
u Transition is closer to heating
transition when shear effects present
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What about high-rate PVT
Solid state data in PVT cooling will
always be wrong
u No instrument can reproduce the
unique frozen layer morphology or
shear state of the injection molding
process
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Current Compromise
Use PVT heating data
u Reasonable transition location
u Good representation of solid state PVT
behavior
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Shrinkage in simulation
Change in volume
in PVT data on
cooling
Starts at melt-solid
transition- Ttrans
249
219
189
159
129
99
69
40
50
100
150
200
1.0000
V
o
l
u
m
e
T
e
m
p
e
r
a
t
u
r
e
P
r
e
s
s
u
r
e
Ttrans
b5
Tmelt
Teject
Finished part
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Consequences
Small changes in Ttrans=large
change in shrinkage
Must be grounded in PVT data of
an injection-molded part
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Melt-Solid transition
DSC based methods
u Easy to get high cooling rates
u Quiescent material
Shown to be not-representative
u Transitions are shear rate dependent
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Melt-Solid transition
DMA based methods
High shear rate can be applied
Slower cooling rates
Also measures temp sensitivity of
viscosity
Set Ttrans based on modulus-
material too stiff to flow
(See Lobo MUG2000)
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DMA for Semi-crystalline plastic
1.E+3
1.E+4
1.E+5
100 120 140 160 180 200
Temp (C)
E
t
a

(
P
a
.
s
)
Ttrans b5
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Unified Material Model
Capillary Viscosity at Process temp
DMA cooling experiment at slow
rate high frequency
u Ttrans, b5
u Temp sensitivity of viscosity (D1, D2)
PVT in heating at same slow rate
Thermal conductivity and specific
heat transitions shifted to Ttrans